. In part, this reflects the ability of carbon capture to manage and eliminate the by-product process chemical remissions from iron ore refining as well as emissions from high-temperature heat. } The innovative smelting reduction process with CCUS, which negates the need to use coking coal a resource that is in short supply in India accounts for a further 26%. Charcoal Behaviour by Its Injection into the Modern Blast Furnace. font-weight: normal; The inherent difficulty of steel decarbonization will require innovation in policy and market design that embrace multiple options and possibly all options. Other assumptions that may be applied include (1) zero-carbon electricity supply, (2) ore fines to avoid agglomeration, (3) fine coal to avoid coking. flex-flow: row wrap; https://www.ipcc.ch/sr15/. As shown in table 2, DRI-EAF plants are much less carbon intensive than traditional BF-BOF route, and deep electrification via DRI-EAF replacement in table 11 could significantly reduce carbon emission from steelmaking in two ways: DRI-EAF is technically available and could play an essential role for decarbonizing steelmaking industry. left: 0; margin-top: 8px; } margin-top: 8px; Steel production typically happens in two steps: First, iron ore is turned into iron, e.g. Chemical Engineering Journal, 394, 124943. .view-resource-library2 .views-row { Blast Furnace - Basic Oxygen Furnace (BF-BOF): This is the dominant steel production route in the iron and steel industry, involving the reduction of iron ore to pig iron in the blast furnace. In Blast Furnace Ironmaking Analysis, Control, and Optimization (pp. Effect of Woody Biomass Addition on Coke Properties. These include (a) partial or complete substitution of fossil fuels with low carbon hydrogen or biofuels, (b) CCS retrofits, (c) replacement of current electricity supplies with low-C electricity, (d) low-carbon biomass substitution of coke with biocoke or charcoal, and replacement of gas- or coal-based DRI plants with biogas or zero-c hydrogen. content: ""; CO2 capture in industries and distributed energy systems: Possibilities and limitations. jQuery(this).parent('.views-exposed-widget').addClass('clicked'); (2020, December 28). This is chiefly due to the large volumes and high concentrations of CO2 at many iron & steel facilities and the small number of large emitting sources within integrated plants. opacity: 1; https://www.bioboost.eu/uploads/files/bioboost_d1.1-syncom_feedstock_cost-vers_1.0-final.pdf, Kuramochi, T. (2011). As many have documented, biomass must be grown, harvested, processed and transported with minimal life-cycle CO2 emission for it to achieve substantial CO2 reductions through fossil fuel substitution [(DOE, 2016)] and some biomass has a documented low life-cycle carbon footprint under the correct operational circumstances. ICEF Industrial Heat Decarbonization Roadmap. worldstainless has issued a report to clarify what emissions exist and where they originate from. Vogl, V., Ahman, M., & Nilsson, L. (2018). Additional emissions reductions would require either carbon capture and storage (CCS) retrofits (see next section) or revolutionary approaches based on electrical primary production. Mehmeti, A., Angelis-Dimakis, A., Arampatzis, G., McPhail, S. J., & Ulgiati, S. (2018). This project provides a clear example of how other gas-based DRI plants might be decarbonized. All details can be found in the report here. Metallurgical and Materials Transactions B, 44, 447458. Yilmaz, C., Wenderstorf, J., & Turek, T. (2017). margin-top: 8px; Since electricity is the only energy source during the whole production process, the carbon footprint is solely determined by the carbon footprint of electricity. For a typical EAF, direct emissions are usually around 0.06-0.1 t/t; indirect emissions can add a further 0.4 t/t CO2. Charcoal TFT research February 2015. https://silo.tips/queue/charcoal-tft-research?&queue_id=-1&v=1609406528&u=MTQ0LjM0LjE2OS4yNTM=, Ueki, Y., Nunome, Y., Yoshiie, R., Naruse, I., Nishibata, Y., & Aizawa, S. (2014). Towards More Sustainable IronmakingAn Analysis of Energy Wood Availability in Finland and the Economics of Charcoal Production. Governments can help by providing RD&D funding, creating a market for near zero-emission steel, adopting policies for mandatory CO2 emission reductions, expanding international cooperation and developing supporting infrastructure. Production of a ton of steel generates almost two tons of CO2 emissions, according to steel industry figures, accounting for as much as 5 percent of the world's total greenhouse-gas emissions. Chemeca 2011: Engineering a Better World. https://www.nrcan.gc.ca/energy/efficiency/industry/processes/energy-systems/metallurgical-fuels/5619?wbdisable=true. On a systems level, the challenge is multiplied by the additional power requirements necessary to run the substitute plants. border-right: 3px solid #fff; For the stainless steel industry, scrap has a high intrinsic value. Production of the hydrogen process is depended on the availability of clean electricity or carbon emission prices. #views-exposed-form-resource-library2-page #edit-combine-wrapper .views-widget Life cycle assessment of biomass densification systems. margin-top: 2em; The BF-BOF pathway converts raw iron ore to pig iron and then to steel HM - while EAF converts both steel scrap and sponge iron to steel HM. margin-top: 1.6em; Stainless Steels and CO2: Industry Emissions and Related Data. flex: 1 1 50%; width: calc(100%); This study covers the integrated route carbon emission and energy consumption, where assumptions are listed in table 1. While modest decarbonization is possible by substituting todays electric power supplies with low-C electricity, it is not possible to completely electrify existing facilities. improving manufacturing yields) and those downstream of the sector (e.g. H2 production consumes 6% of global natural gas and 2% of global coal, emitting 830 million tons of CO2. https://ec.europa.eu/research/index.cfm?eventcode=80BB405C-DA08-56D3-800BC46FC9A6F350&pg=events. Yilmaz et al. [1] This report does not include further treatment, such as finishing and alloying, Zhiyuan Fan is a research associate at the Center on Global Energy Policy (Full Bio), Dr. Julio Friedman is aNon-Resident Fellow at the Center onGlobal Energy Policy (Full Bio). Schematics of green H2 feeding into BF is shown in figure 5. Cost increase per ton steel HM with hydrogen substitution and carbon tax avoided. The total cost of DRI depends to a large extent on hydrogen prices. flex-wrap: wrap; In the Sustainable Development Scenario innovative CCUS-equipped blast furnace concepts are retrofitted to efficient new blast furnaces that are installed during a period in which few low-carbon alternatives are available. width: 100%; Both green and blue hydrogen can already deliver energy and reduction agent in a safe and close to carbon neutral way. However, scrap cannot fulfil the sectors raw material input requirements alone because steel production today is higher than when the products that are currently being recycled were produced. The CO 2 emission intensity of the steel plant is calculated by the net CO 2 emission from the plant using the boundaries divided by the amount of crude steel production of the plant. } opacity: 1; opacity: 1; #block-views-exp-resource-library2-page .advanced-filters .clicked .views-widget { The scrap-based production system in which the bulk of used raw materials are end-of-life stainless steels and/or similar alloy materials that are recycled to produce new stainless steels. Sustainability, 10, 2323. TFT Research. Some additional energy would also be needed for a preheating step (Table 3) to meet operational temperature requirements [(Vogl et al., 2018)]. } } else { Hulst, N. van. 704.38 short ton: 109.98: 49.89: Tire-derived fuel b: 189.53: 85.97: Waste oil b: 22.51 gallon . Since the same zero-carbon electricity source is assumed for all production pathways, the carbon abatement costs ($/ton-CO2) are the same. This could serve to develop international low-emission production standards for steel among buyers & sellers (akin to the Montreal Protocol), potential avoiding future challenges to the International Monetary Fund. #block-views-exp-event-search2-block .views-submit-button, #block-views-exp-event-search2-block-1 .views-submit-button { min-height: unset; This means that recycling alone cannot be relied upon to reduce emissions from the sector to the extent needed to meet climate goals. The actual abatement of CO2 using bio-charcoal is sensitive to many factors, most importantly LCA and LUC of the biomass. The worlds guidebook on clean energy technologies, Keep up to date with our latest news and analysis by subscribing to our regular newsletter. z-index: 1; Mitigation and Adaptation Strategies for Global Change, 21, 391402. In the Net Zero Scenario, near zero-emission production the H2-DRI route and CCUS-equipped routes commences at scale in the 2020s, accounting for more than 5% of primary production by 2030. padding-left: 0; Combining these approaches could eliminate CO2 emission from coking, sintering, and pelletizing completely, yielding in maximumly 20% CO2 decrease for a facility. Steel is deeply engrained in our society. H2 injection abatement potential (%) self reference, Zero-C electricity abatement potential (%) self reference, Combined abatement potential (%) self reference, Combined abatement potential (%) BF-BOF reference. Bio-charcoal replacing coal in BF-BOF under different cost/carbon footprint. The table below identifies typical CO2 production volumes per tonne of output for each steelmaking process stage. width: 50%; Progress in Energy and Combustion Science, 33(6), Pages 580-609. Barati, M. (2010). (2020). The above summaries cover the overwhelming majority of world steel production (>99%). Table 14. This compares with a global average of 1.69 tons and an integrated steelmaking average of 2.15 tons. Green H2 injection could be regarded as a version of electrification penetration as well, since it adopts zero-carbon electricity to be replace fossil fuel (see Combined technologies set section). First in fossil-free steel. } ***Conversion of DRI to hot metal in weight is assumed 90% (2018 data, 100 Mt DRI [(Midrex, 2019)] produced 90 Mt HM [(Worldsteel Association, 2019)]). margin-right: 60px; HIsarna is a direct bath-smelting reduction technology that combines coal preheating and partial pyrolysis with the smelting reduction vessel working as its core reaction container [(Stel et al., 2013)]. https://ucanr.edu/sites/WoodyBiomass/newsletters/InfoGuides43122.pdf. } Policy portfolios will be diverse, but the following recommendations serve as a starting point for those seeking to effect change and accelerate the transition: The projection horizon of this technology roadmap extends to 2050, but governments and decision makers should have 2030 firmly in mind as the critical window to accelerate the transition. Dey, N., Prasad, A., & Singh, S. (2015). In the proposed process, the near 100% oxygen blast replaces traditional hot blast, which produces top-gas enriched in CO2 for more efficient capture. To ensure that the deployment of near zero steel production technology is not delayed, policy makers must begin planning and developing infrastructure, including building social acceptance, fostering new interregional and international collaboration, reducing planning times and ensuring affordable access to this infrastructure. background-color: #3488ca; . In this report, if the cost is represented by a single value, its the mean value of the range of the cost. are not the same for bio-charcoal as coal or coke, and manufacturing performance standards may not be guaranteed. Although industrial sector is one of the well-known hard-to-abate sectors to decarbonize, electrification is commonly presented as a decarbonization option. For these cases, zero-carbon electricity penetration could prove a low-cost, high-effectiveness abatement solution by replacing BF-BOF with any other production pathways. width: 35px; If using gas-based DRI production, however, this decarbonization potential is surprisingly high: 78% decarbonized reference to DRI-gas itself and 86% is taking BF-BOF technology as reference. Life Cycle Assessment and Water Footprint of Hydrogen Production Methods: From Conventional to Emerging Technologies. position: relative; The key basis to apply multiple technology sets is to increase the decarbonization potential: As identified, H2, biomass, zero-carbon electricity, and CCS retrofit are all promising options for steelmaking decarbonization. Estimated demand for each source of bio-charcoal is slightly different due to its product carbon content (i.e., one cannot assume 1:1 replacement). If operated until the end of their typical lifetime under current conditions, these and other assets in the steel industry could lead to around 65GtCO2 of cumulative emissions. https://www.cslforum.org/cslf/sites/default/files/documents/AbuDhabi2017/AbuDhabi17-TW-Sakaria-Session2.pdf, Santos, S. (2014). 1.86 billion metric tons The amount of steel produced in 2020. border-radius: 0; CO2 capture from the industry sector. } padding-top: 10px; position: absolute; The construction of homes, schools, hospitals, bridges, cars and trucks to name just a few examples rely heavily on steel. Hydrogen uses in ironmaking. All steps matter: harvesting from woody biomass sources (LUC), biomass processing emission control (LCA), and charcoal production method. Improvements in operational efficiency, including enhanced process control and predictive maintenance strategies, together with the implementation of best available technologies contribute around 20% of cumulative emissions savings in the Sustainable Development Scenario. (2020). Oxygen blast and CCS retrofit is the prerequisite to recycle the top-gas and therefore subjected to additional capital cost. (2020). Effect of hydrogen addition on reduction behavior of iron oxides in gas-injection blast furnace. The U.S. EPA has found that a typical 22 MPG gas-based car emits about 5 tons of carbon dioxide per year. @media screen and (max-width: 899px) { With a $30/ton-CO2 carbon price, MOE could be cost competitive with $35/MWh electricity [(Boston Metal, 2020)]. //-->. Martin Kueppers, Contributors This production system is aligned to geographical locations where the availability of end-of-life materials and scrap is high. margin-bottom: 3em; (2000). Minerals Engineering, 20(9), 854861. Hydrogen production from biomass is highly uncertain for 1) various feedstocks 2) complicated processes, and 3) cost uncertainty. (2016). It appears that coal-based DRI production (i.e., India, Malaysia) can accept 100% biomass substitution and can tolerate a wide range of feedstocks: straw, normal charcoal, and bamboo charcoal. } (2018). For intermittent systems with lower capacity factors, additional generation (oversupply) would be needed with additional costs for storage and/or with firm power provided by fossil resources, reducing the overall system effectiveness (see table 12). The net downstream savings were found to be 5040-19 340 kg CO (2)-equivalents tonne (-1) of treated aluminium and 560-2360 kg CO (2)-equivalents tonne (-1) of treated steel. #views-exposed-form-resource-library2-page #edit-title-wrapper .views-widget } Oxygen Blast Furnace (OBF), is less carbon intensive for its inherent ability to capture and disposal of the CO2 of the BF top gas, which implies additional cost as $56/to-CO2 [(Wilcox, 2020)]. Sustainable Energy Fuels, 4, 29672986. The geography of hydropower potential is highly correlated to current and future steel production (i.e., Asia Pacific and other developing economies) but not at sufficient generation levels. Depending on the type, location and availability of stainless steel scrap, production via the EAF route can be economically advantageous. margin: 0 0 52px; CCS retrofit for DRI system is similar to BF retrofit: high CO2 concentration leads to more efficient CO2 capture.
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